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Characterization of Brake Pads by Variation in Composition of Friction Materials

Authors:
Nagesh S N at Ramaiah Institute of Technology
Nagesh S N
C. Siddaraju at Ramaiah Institute of Technology
C. Siddaraju
Siddareddy V Prakash at CMR Institute of Technology
Siddareddy V Prakash
Ramesh M R at National Institute of Technology Karnataka
Ramesh M R
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Abstract

Brake pads are the most important component of an automobile braking system. It help in smooth retardation of a vehicle and finally bringing it to halt. Brake pads convert the vehicle's kinetic energy into thermal energy by friction. The effectiveness of the brakes depends completely on frictional material used, which in turn affect the performance of the brake pads. In the present investigation the brake pads were produced by varying constituents (wt%) of the existing composition and new formulations were made with other friction materials. The brake pads were manufactured using powder metallurgy technique. The manufactured brake pads were tested for coefficient of friction, wear, shear strength, hardness and micro structural analysis. The various test results were compared with the existing brake pad composition. Hard friction materials were found in brake pads wear at a lower rate but results in higher brake noise. Brake pads S2 and S4 showed results which are equivalent to the existing brake pad.
characterization of brake pa
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Characterization of Brake Pads by Variation in Composition of Friction Materia
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Procedia Materials Science 5 ( 2014 ) 295 – 302
Available online at www.sciencedirect.com
2211-8128 © 2014 Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/3.0/).
Selection and peer-review under responsibility of Organizing Committee of AMME 2014
doi: 10.1016/j.mspro.2014.07.270
ScienceDirect
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© 2014 Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/3.0/).
Selection and peer-review under responsibility of Organizing Committee of AMME 2014
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... Binders maintain structural integrity, fillers stabilize friction, and friction modifiers provide structural support. These are essential components in brake linings, holding ingredients together, and cost-effectiveness [2]. Friction brakes convert vehicle kinetic energy into heat, slowing it down. ...
... Density Test The sample densities were determined using a digital weighing machine, and their volumes were calculated using equation (2). (2) where m is the mass of the test piece (g) and v is the volume of the test piece (cm 3 ) ...
... Density Test The sample densities were determined using a digital weighing machine, and their volumes were calculated using equation (2). (2) where m is the mass of the test piece (g) and v is the volume of the test piece (cm 3 ) ...
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... Binders maintain structural integrity, fillers stabilize friction, and friction modifiers provide structural support. These are essential components in brake linings, holding ingredients together, and cost-effectiveness [2]. Friction brakes convert vehicle kinetic energy into heat, slowing it down. ...
... Density Test The sample densities were determined using a digital weighing machine, and their volumes were calculated using equation (2). (2) where m is the mass of the test piece (g) and v is the volume of the test piece (cm 3 ) ...
... Density Test The sample densities were determined using a digital weighing machine, and their volumes were calculated using equation (2). (2) where m is the mass of the test piece (g) and v is the volume of the test piece (cm 3 ) ...
DEVELOPMENT OF COMPOSITE MATERIALS FOR TRICYCLE BRAKE PADS
Article
Full-text available
  • May 2024
Coconut fiber and rice dust are locally sourced, developed, and evaluated as agro-waste materials to replace carcinogenic asbestos fibers in brake pad production. The process involves crushing, grinding, and sieving coconut fiber into a powder, mixing it with steel dust, carbon black, and epoxy resin, filling a mould, adding hardener, and pressing and curing samples at 250 °C. The produce is tested for mechanical properties, with optimal brake pad properties achieved using a 100µm sieve grade, enhancing interfacial bonding between resin and coconut shell particles. The hardness, compressive strength, ash content, specific gravity, wear rate, and water absorption values were found to be 258, 113 N/mm2 , 40%, 1.91, 3.23 mg/m, and 0.63%. The study found that coconut shell has qualities similar to those needed for brake pad material and asbestos replacement in brake pad production. Coconut shell, with its 100µm particle size, has the potential to replace asbestos-based brake pad manufacturing, reducing harmful components and environmental impact.
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... According to Nagesh et al. [41], a brake pad is a mixed material consisting of various constituents that improve the brake performance under various conditions such as high or low temperatures. These components improve brake pad durability, increase pad strength and rigidity, and reduce brake pad noise during their operation. ...
... Lawrence and Paul [4] stated that brake pad material composition is in three categories: metallic, semi-metallic and non-asbestos organic (NAO) materials. Many studies have been done on the nanocomposites as well as several types of fibers such as glass, ceramic, metallic and mixtures of carbon fiber for production of brake pad applications [17,41,[53][54][55][56][57][58][59][60]. The fibers mentioned above are widely used as fillers or reinforcements material to produce NAO brake pads [4,54]. ...
RESEARCH, DEVELOPMENT AND TESTING OF BRAKE PAD MATERIALS FROM BIOMASS-BASED NANOCOMPOSITES
Thesis
Full-text available
  • Jan 2021
Many variables affect braking systems in the automotive industry, including component geometry, brake materials, component interactions, and various operating conditions. The current research trend in the automotive industry is to use waste as raw material for nanocomposite materials in automobile applications. A novel bio-based hybrid nanocomposite (BHN) brake pad has been developed and investigated to serve as a functional replacement for metallic, ceramic, and hazardous asbestos-based brake pad materials. Carbon-based nanocomposites such as carbon nanospheres, carbon nanotubes, carbon nanosheets, and carbon nanofibers, etc., have attracted wide attention from researchers since their discovery. Carbon nanospheres (CNSs) are among the novel carbon nanostructures distinguished for their potential use in many areas, for instance lithium-ion batteries, electrodes in super capacitors, different parts of automobiles and adsorbents. In this study, CNSs were synthesized from palm kernel fiber (PKF) activated carbon using a simple physical activation method under CO2. The BHN consisted of a matrix of carbon nanomaterials from PKF which acted as the filler material, epoxy resin which acted as the binder material, together at a nanoscale to produce brake pad. The temperature effect on synthesized nanomaterials was investigated using transmission electron microscopy (TEM), x-ray diffraction (XRD), scanning electron microscopy (SEM), energy dispersive x-ray spectroscopy (EDX), Fourier transform infrared microscopy (FTIR), and thermo-gravimetric analysis (TGA). The SEM results showed the highest purity, and the largest number of CNSs were formed at a synthesis temperature of 1000 °C. The tribological properties of BHN brake pads were studied and compared with conventional (CON) brake pad material. The BHN brake pads exhibited low wear rate compared to the CON brake pads, while the coefficient of friction (COF) of the BHN brake pad samples (0.3 to 0.5) were within the SAE J661 CODE standard. The results showed that the brake pad performance differed with each pad formulation. The BHN brake pad material had excellent performance in most of the analyses when compared to the CON brake pad material. The mechanical properties of the BHN brake pad such as compressive strength, compressive modulus, hardness and impact strength were tested. The nanocomposite material showed a higher impact strength and compressive strength compared to the (CON) brake pads. The hardness of the material of the two brake pads was statistically akin. Furthermore, the performance of oil and water absorption, thermal stability as well as degradation of the BHN brake pad were determined. The results showed that the BHN brake pad material had low oil absorption rate and low moisture water absorption rate. The BHN brake pad showed thermal stability within the range 300 °C to 400 °C, which are within the standard temperature range. Result from SEM analysis carried out on the worn surfaces of the BHN brake pads reveals a tougher structure than SEM of the worn surfaces of the CON brake pads. Dynamic mechanical analysis (DMA)results showed that at a temperature between 55 °C and 105 °C, the 𝑇𝑎𝑛 𝛿 magnitude of BHN was higher due to the loss modulus supremacy over the storage modulus. In addition, in the temperature range 105 °C to 190 °C, the storage modulus and the loss modulus was as low as that of the CON, and the BHN 𝑇𝑎𝑛 𝛿 magnitude reduced. Excellent mechanical and tribological properties of BHN brake pad was achieved at 0.3 % CNS.
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... Fibers such as: organic (Kevlar, jute), inorganic (lapinus), metallic (copper), ceramic (glass), natural (cellulose) and their various combinations are used in brake pads. Metal oxides and carbides are used as abrasives, whereas graphite and metal sulfides are common-ly used as lubricants [10][11][12]. ...
Mechanical and tribological investigation of jute fiber reinforcement in organic automotive brake pads and water repellency gain in natural fiber reinforced pads
Article
Full-text available
  • Mar 2025
Many studies have shown that the materials used in the composition of brake pads are directly related to friction, wear mechanisms and tribological behavior. Heat-resistant jute fiber is an organic fiber that can be added to the composition of brake pads that can achieve good braking. In the study, pads were produced by adding different amounts of jute fiber using phenolic resin with powder metallurgy method and the results were compared with pads without jute fiber. It was observed that adding 5% jute fiber in addition to aramid fibers used in brake pad manufacturing had positive effects on friction coefficients, friction fluctuations and wear mechanism. At the same time, water absorption values of natural fibers were reduced by 30% and water repellency was provided to the pads. According to sample A, the density of JF3 decreased by 25.4% and shear strength by 39%. The hardness value is at the standard value used in the market.
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... The fade is the temporary loss of braking due to the decrease in COF as a result of high temperatures between the sliding surfaces, while the recovery cycle is the restoration of the braking performance when the friction surface is cooled down. [38][39][40][41] The analysis of the COF for composite brake linings is not a sufficient indicator of the braking performance by itself. Not only analysis of fluctuations in COF during high-temperature braking applications but also wear rate, which also indicates the lifetime of the material, must be taken into consideration. ...
Influence of fly ash and waste tire rubber particles on mechanical and tribological properties of composite brake linings
Article
Full-text available
To investigate the influence of waste tire rubber (WTR) and fly ash (FA) on mechanical and tribological properties of composite brake linings, 8 different formulations of 8–40 wt% FA and 10–12 wt% WTR were selected. The mechanical tests showed that high amounts of resin and FA result in the highest hardness. The inclusion of WTR, decreased hardness and internal shear strength; however, increased the acetone extraction and resistance to coefficient of friction (COF) fluctuations. With the use of WTR, steady COF fluctuations with the temperature changes are achieved. The tribological properties were evaluated with both a drum‐type and disc‐type dynamometer by the SAE‐J661 standard. Reduced COF fluctuations were observed in <15 wt% FA and 10 wt% WTR containing samples. The highest COF was obtained for the 14 wt% FA and the lowest wear rate for the samples containing 8 wt% FA. The brake composites exhibited consistent COF in the range of 0.34–0.52, and wear rates lower than 7 wt%. Two compositions containing 40 and 25 wt% FA (no WTR), and one containing 10 wt% WTR and 8 wt% FA provided the best results. Finally, four best compositions were selected and worn surfaces were analyzed with SEM after full‐scale dynamometer tests. Highlights Three composites with high waste percentage were successfully manufactured Fly ash and waste rubber are used without any post‐processing to cut costs Waste rubber increased resistance to COF fluctuations with temperature change Full‐scale dynamometer tests are performed for friction and wear properties Worn surfaces were analyzed with SEM method
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... The test conditions involved speed and brake pressure ranging from 6.66 to 13.82 m/s and 0.2-0.6 MPa, respectively (Nagesh et al. 2014). This allowed us to assess the brake pads under different conditions. ...
Optimizing Brake Pad Performance of a Composite Materials Prepared with Smilax Zelanica/Glass Fiber and Nano Silica Across Diverse Sieve Variations
Article
Full-text available
  • May 2024
This groundbreaking study aimed to enhance the efficiency and durability of brake pads by developing a novel composite material composition. The research focused on integrating alkali-treated smilax zelanica/glass fiber reinforcements with nano silica to improve the mechanical, structural, and performance properties of brake pads. Comprehensive tests were conducted to evaluate friction, wear, and shear characteristics under various conditions. The results demonstrated significant enhancements in these properties, attributed to the synergistic effects of the composite materials. Scanning electron microscopy (SEM) analysis provided detailed insights into the microstructure and failure mechanisms, confirming strong bonding between the reinforcing fibers, Nano silica particles, and the matrix material. The study’s methodology involved fabricating brake pad samples with different proportions of sieves measuring 180 μm and 250 μm, varying the ratio of matrix to reinforcements. Among these, the combination of 70% matrix and 30% reinforcements exhibited superior mechanical properties. Samples underwent chemical treatment and sieve processes before formulation, blending filler, fiber, binder, and frictional additives. Hydraulic pressing and curing processes were employed to produce the final brake pads. Physical and mechanical testing included density, porosity, hardness, and impact strength assessments. Results showed that samples with smaller particle sizes exhibited higher density, lower porosity, greater hardness, and superior impact strength, indicating improved mechanical properties. Performance testing using a brake pad test rig demonstrated the composite material’s promising efficiency and sustainability. The observed improvements signify a significant advancement in brake pad technology, offering durable, efficient, and environmentally friendly solutions for the automotive industry. SEM analysis further confirmed variations in microstructure among samples, with denser structures exhibiting better mechanical properties. Comparison with asbestos-based brake pads showed superior performance of the composite materials in terms of wear rate, tensile strength, hardness, compressive strength, friction coefficient, thermal conductivity, specific gravity, and resistance to swelling in oil and water. The study highlights the efficacy of alkali-treated smilax zelanica/glass fiber and nano silica composite materials in improving brake pad performance compared to conventional asbestos-based materials. The research provides valuable insights into the development of sustainable alternatives for brake pad manufacturing, contributing to enhanced safety and performance in vehicle braking systems.
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MANUFACTURING AND DEVELOPMENT OF LOW COST ASBESTOS-FREE BRAKE PAD COMPOSITE MATERIAL
Article
Full-text available
  • Jan 2019
Brake materials have special features such as corrosion resistance, light weight, long life, low noise, stable friction, low wear rate, and acceptable cost versus performance. The aim of this research is formulation and manufacture of frictional composite material with low cost and high properties for brake pad applications. Frictional material used in brake pads is made of four subcomponents that play different roles. These are; abrasive materials to modify friction, lubricants to stabilize developed friction, binders to hold different constituents together and prevent disintegration and fillers to improve manufacturability as well as to lower the cost. The fabricated friction material with different chemical composition has been tested tribologically and mechanically to measure the performance under different conditions. Tests have been carried out are; hardness, tensile, cross brake, wear rate. All results of these tests presented in this paper showed that the coefficient of friction increased with increasing abrasive content. From the results, it is indicated that the proper reinforcement percentage as well lubricant one's in addition to enough content of binder resin in the material composition result in high values of hardness, internal shear strength, tensile strength and result in good wear properties. More details are discussed in this paper. INTRODUCTION A brake is a device which inhibits motion. Most brakes use friction to convert kinetic energy into heat, though other methods of energy conversion may be employed. A friction brake is a type of an automotive brake that slows or stops a vehicle by converting kinetic energy into heat energy, via friction. The braking heat is stored in the brake drum or disc while braking, then conducted to the air gradually. The modern automotive brake system has been refined and high development of brake pad material is achieved in recent years, [1]. The compositional design of friction materials is a well-known problem of multi-criteria optimization that involves handling prime classes of constituents, [2]. Formulations of such materials comprised four different categories of materials, where compositional design of such materials is complicated further by the requirement that the materials should exhibit some functional requirement in order to perform their function properly such as; high friction-coefficient stability, low wear of the brake pad disc and good wear resistance and long life span, [1]. According to Nicholson (1995), the elements of the friction material constituents are categorized into friction additives that determine the frictional properties of brake pad. They contain a
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Sliding Wear Characteristics of Zn-15Sn Alloy with Nano B4C Reinforced Composites
Article
Full-text available
  • Jul 2024
In the current investigation, high pin-on-disc wear testing equipment was used to examine the impact of modest additions of nano B4C on the wear behaviour of a Zn alloy (85Zn-15Sn). Zn-Sn alloy behaviour at a constant SD of 2000m under pressures (10N, 20N, 30N, and 40N) and sliding speeds (1.4, 1.8, 2.3 and 2.8 m/s) was investigated. Microanalysis with SEM/EDX was used to characterise the matrix and worn surfaces. According to the results, the wear rate of Zn alloy rises with rising pressures, sliding speeds and distances in all situations examined and lowers with an additional level of 8 weight per cent B4C to the Zn alloy when tested. This is brought on by the partial refinement of Zn dendrites, as well as the precipitation hardening of solid solutions. The worn surface investigation suggests that the creation of a thick oxide layer during sliding enhances tribological features.
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Effects of alumina in nonmetallic brake friction materials on friction performance
Article
Full-text available
  • Jan 2009
The effects of alumina (Al2O3) as an abrasive on brake friction performance and friction layers of nonmetallic brake friction materials were evaluated. Five experimental compositions containing from 0 to 14.6vol% alumina were tested (Al2O3—0, 3.4, 5.6, 9.0, and 14.6vol%). The experimental results indicated that alumina enhances friction coefficient and improves wear performance. The formation and development of friction layers were characterized using X-ray fluorescence spectrometry and scanning electron microscopy with energy dispersive X-ray analysis. Phenomena of baryte film and transferred iron-containing film formed on the friction surfaces were observed. Baryte films were detected on specimens containing from 0 to 5.6vol% alumina. Iron-containing films were detected on surfaces of all alumina-containing specimens but not on the material without alumina. The role of abrasive in nonmetallic friction materials was studied in relation to formulation, friction performance, and friction surfaces.
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Effects of Mixing the Steel and Carbon Fibers on the Friction and Wear Properties of a PMC Friction Material
Article
  • Apr 2010
Friction, fade and wear characteristics of a PMC friction material containing phenolic resin, short carbon fiber, graphite, quartz, barite and steel fiber were investigated through using a small-scale friction testing machine. Four different friction materials with different relative amounts of the carbon fiber and steel fiber were manufactured and tested. Comparing with our previous work which contained only steel fiber as reinforcement, friction characteristics such as fade and recovery and wear resistance were improved significantly by adding a small amount of carbon fiber. For the mixing of carbon and steel fiber, the best frictional and wear behavior was observed with sample containing 4 weight percentage carbon fiber. Worn surface of this specimen was observed by optical microscopy. Results showed that carbon fibers played a significant role in the formation of friction film, which was closely related to the friction performance. The brake pad with Steel fibers in our previous work, showed low friction coefficient and high wear rate. In addition, a friction film was formed on the surface with a relatively poor quality. In contrast, the samples with mixing the steel and carbon fiber generated a stable friction film on the pad surface, which provided excellent friction stability with less wear.
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Friction and wear behavior of carbon fiber reinforced brake materials
Article
  • Mar 2009
A new composite brake material was fabricated with metallic powders, barium sulphate and modified phenolic resin as the matrix and carbon fiber as the reinforced material. The friction, wear and fade characteristics of this composite were determined using a D-MS friction material testing machine. The surface structure of carbon fiber reinforced friction materials was analyzed by scanning electronic microscopy (SEM). Glass fiberreinforced and asbestos fiber-reinforced composites with the same matrix were also fabricated for comparison. The carbon fiber-reinforced friction materials (CFRFM) shows lower wear rate than those of glass fiber- and asbestos fiber-reinforced composites in the temperature range of 100°C-300°C. It is interesting that the frictional coefficient of the carbon fiber-reinforced friction materials increases as frictional temperature increases from 100°C to 300°C, while the frictional coefficients of the other two composites decrease during the increasing temperatures. Based on the SEM observation, the wear mechanism of CFRFM at low temperatures included fiber thinning and pull-out. At high temperature, the phenolic matrix was degraded and more pull-out enhanced fiber was demonstrated. The properties of carbon fiber may be the main reason that the CFRFM possess excellent tribological performances.
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